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ISO 9001 REGISTERED & CERTIFIED LIMITED WARRANTY This Limited Warranty is given exclusively to: Name Address Telephone No. by Unique Concepts Ltd. (“Unique Concepts”) in respect of the following product(s) manufactured by it (the “Products”): Subject to the conditions and restrictions contained in this Limited Warranty, Unique Concepts warrants to the Customer that the Products are free from defects in materials and manufacturing for a period of sixty (60) months and in workmanship under normal use and service for a period of twelve (12) months from the date the Products are purchased by the Customer, in new and unused condition, from Unique Concepts or its agent (the “Warranty Period”). Unique Concepts’ entire liability and the Customer’s exclusive remedy regarding any such defects is limited to the repair or replacement of the defective Products (as Unique Concepts, in its sole discretion, deems appropriate) which are returned to Unique Concepts in accordance with the procedures set forth below. Terms and Conditions 1. This Limited Warranty will be void unless: (a) this Limited Warranty is fully completed by or on behalf of the Customer and returned to Unique Concepts within fourteen (14) days following the date the Customer purchases the Products, by registered mail addressed to: Unique Concepts Ltd., 1500 King Edward Street, Winnipeg, Manitoba, R3H 0R5 (the "Manufacturer’s Address”); (b) written notice of any defect is delivered to the Manufacturer’s Address by registered mail within five (5) days after any defect in the Products becomes apparent; and (c) any defective Products in respect of which the Customer wishes to make a warranty claim are delivered to Unique Concepts, with all postage or freight charges prepaid, within the Warranty Period and no later than fourteen (14) days after any defect in the Products becomes apparent. 2. This Limited Warranty shall not apply to any Products which have been used with unapproved assemblies or sub-assemblies, or which have been customized or modified, altered, damaged or misused. 3. Following the repair or replacement of any defective Products in respect of which a warranty claim is validly made by the Customer, or, alternatively, following the date Unique Concepts determines either that the warranty given hereby has been voided or that the returned Products do not exhibit any defects in materials or workmanship, Unique Concepts will return the Products to the Customer. All such shipments will be made to the Customer’s address listed above, and will be at the Customer’s sole expense. I 4. The Customer will incur all risk of loss, theft or damage to the Products during shipment to Unique Concepts and during their subsequent return to the Customer. Without limiting the foregoing, the common carrier chosen by Unique Concepts to return the Products to the Customer will be deemed to be an agent of the Customer. 5. If, on its inspection of any Products returned to it by the Customer, Unique Concepts determines that such Products require maintenance or repairs which are outside the scope of its warranty obligations. Unique Concepts may contact the Customer with a view to obtaining authorization (which may be written or oral) to complete such maintenance or repairs at rates then customarily charged by Unique Concepts to its customers. The Customer hereby releases and indemnifies Unique Concepts, together with its directors, officers, agents, employees, successors and assigns, and anyone else who has been involved in the inspection of the Products returned by the Customer, from all claims, losses, expenses and damages (including damages for loss of business profits, business interruption, loss of business information, loss of health or for any other loss whatsoever) arising directly or indirectly, as a result of the failure by Unique Concepts to perform or adequately perform any maintenance or repairs which are outside the scope of its warranty obligations hereunder, whether or not resulting from any negligent or improper inspection of such Products, or from the failure of the Customer to authorize the performance of such maintenance or repairs. 6. THE WARRANTY SET OUT HEREIN IS THE ONLY WARRANTY OF ANY KIND, EITHER EXPRESS OF IMPLIED, STATUTORY OR OTHERWISE (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) THAT IS MADE BY UNIQUE CONCEPTS. WITHOUT LIMITING THE GENERALITY OF THE FOREGOING, UNIQUE CONCEPTS DOES NOT WARRANT THAT THE PRODUCTS WILL MEET ALL REQUIREMENTS OF ALL APPLICABLE LAWS, REGULATIONS OR OTHER ENACTMENTS APPLICABLE IN EACH JURISDICTION IN WHICH THEY MAY BE USED OR STORED, OR THE REQUIREMENTS OF THE CUSTOMER. 7. NO ORAL OR WRITTEN INFORMATION OR ADVICE GIVEN BY UNIQUE CONCEPTS, ITS DEALERS, DIRECTORS, OFFICERS, DISTRIBTORS, AGENTS OR EMPLOYEES SHALL CREATE A WARRANTY OR IN ANY WAY INCREASE THE SCOPE OF THIS LIMITED WARRANTY, AND THE CUSTOMER MAY NOT RELY ON ANY SUCH INFORMATION OR ADVICE. 8. THE CUSTOMER AGREES THAT, TO THE MAXIMUM EXTENT PERMITTED UNDER APPLICABLE LAW, NEITHER UNIQUE CONCEPTS NOR ITS DEALERS, DIRECTORS, OFFICERS, DISTRIBUTORS, AGENTS OR EMPLOYEES, OR ANYONE ELSE WHO HAS BEEN INVOLVED IN THE CREATION, PRODUCTION OR DELIVERY OF THE PRODUCTS, WILL BE LIABLE FOR ANY DIRECT, INDIRECT, CONSEQUENTIAL OR INCIDENTAL DAMAGES (INCLUDING DAMAGES FOR LOSS OF BUSINESS PROFITS, BUSINESS INTERRUPTION, LOSS OF BUSINESS INFORMATION, LOSS OF HEALTH OR ANY OTHER LOSS WHATSOEVER) ARISING OUT OF THE USE OR INABILITY TO USE SUCH PRODUCT, EVEN IF UNIQUE CONCEPTS HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES. 9. The Customer is not entitled to assign this Limited Warranty to any party. To the maximum extent permitted under applicable law, and at its sole discretion, Unique Concepts is entitled to assign its obligations hereunder to any third party. 10. This Limited Warranty is governed by the laws of the Province of Manitoba and will benefit Unique Concepts and its successors and assigns. II ACKNOWLEDGEMENT THE CUSTOMER ACKNOWLEDGES THAT HE/SHE HAS READ THIS LIMITED WARRANTY, UNDERSTANDS IT, AND AGREES TO BE BOUND BY ITS TERMS AND CONDITIONS. THE CUSTOMER FURTHER AGREES THAT THIS LIMITED WARRANTY CONTAINS THE COMPLETE AND EXCLUSIVE STATEMENT OF AGREEMENT BETWEEN THE PARTIES, AND SUPERSEDES ALL PROPOSALS OR PRIOR AGREEMENTS ORAL AND WRITTEN, AND ANY OTHER COMMUNICATIONS BETWEEN THE PARTIES, RELATING TO THE SUBJECT MATTER OF THIS LIMITED WARRANTY. Date Customer WARRANTY VOID IF NOT REGISTERED III UNIQUE CONCEPTS CONFINED SPACE ENTRY/RETRIEVAL UCL ADVANCED PORTABLE FALL-ARREST SYSTEM WARRANTY REGISTRATION FORM & INSPECTION REPORT WARRANTY REGISTRATION (please print) This form must be filled out by the dealer and signed by both the dealer and the customer at the time of delivery. Customer’s Name________________________ Dealer Name________________________ Address________________________________ Address____________________________ City, State/Province, Code__________________ City, State/Province, Code______________ Phone Number ( ____ )____________________ Phone Number ( ____ )________________ Contact Name____________________________ Manufactured by: Unique Concepts Ltd. 1500 King Edward Street Winnipeg, Manitoba, Canada R3H 0R5 Phone Number (204) 694-7432 Toll Free 1-800-455-9673 Model __________________________________ Serial Number ___________________________ Delivery Date ____________________________ DEALER INSPECTION REPORT SAFETY ___ All Fasteners Torqued ___ Check that all fasteners and mechanical components are present ___ Check Winch with Winch Warranty Card ____ No Mechanical Damage ___ Check for finish damage ____ All Labels Installed Correctly and Legible ____ Review Operating and Safety Instructions I have thoroughly instructed the buyer on the above described equipment which review included the Operator’s Manual content, equipment care, adjustments, safe operation and applicable warranty policy. Date ____________________ Dealer’s Rep. Signature _______________________ The above equipment and Operator’s Manual have been received by me and I have been thoroughly instructed as to care, adjustments, safe operation and applicable warranty policy. Date ___________________ Owner’s Signature ___________________________ WHITE YELLOW PINK UNIQUE CONCEPTS DEALER CUSTOMER IV SERIAL NUMBER LOCATION Always give your dealer or distributor the serial number of your UCL ADVANCED Portable FallArrest System when ordering parts or requesting service or other information. The serial number plate is located where indicated. Please mark the number in the space provided for easy reference. MADE IN CANADA Pt#: 12817 Rev.03 SERIAL No. MFG DATE: LOT No. COMPONENT MODEL: SYSTEM MODEL: www.capitalsafety.com SERIAL NUMBER LABEL Model____________________________ Serial Number_____________________ SECTION TABLE OF CONTENTS DESCRIPTION 1 INTRODUCTION 1 2 SAFETY 2 2.1 2.2 2.3 PAGE General Safety Operating Safety Maintenance and Inspection Safety 3 4 4 OPERATING, NEW OPERATOR OR OWNER 3 3.1 3.1.1 3.1.2 3.1.3 3.2 3.2.1 3.2.2 3.2.3 3.2.4 3.3 Portable Fall-Arrest Mast Mounting Bases 13 General Installing the Uni-Anchor Plate Installing the Portable Mounting Bases Set-up of the Portable Fall-Arrest Mast Portable Fall-Arrest Post Accessories General 3.3.2 3.3.2.1 3.3.2.2 14” Anchor Extension Post Set-Up of the 14” Anchor Extension Post Using the 14” Anchor Extension Post 3.3.4 3.3.4.1 3.3.4.2 3.3.4.3 3.4 7 General Setting Up the Portable Fall-Arrest Mast Using the Portable Fall Arrest Mast for HLL Applications 3.3.1 3.3.3 3.3.3.1 3.3.3.2 3.3.3.3 5 14 Anchor Post Davit Arm Assembly Set-Up of the Anchor Post Davit Arm Assembly Using the Davit Arm Assembly Rescue Mounting Brackets for Winch and SRL Set-Up of the Mounting Brackets Using the Mounting Brackets Re-Positioning the Mounting Brackets Storage 19 i 4 MAINTENANCE AND INSPECTION 4.1 Maintenance 4.2 Inspection 4.3 Inspection Log 5 LABELS 5.1 20 23 Warning Labels 6 SPECIFICATION SHEETS 24 7 REPLACEMENT PARTS 31 ii Congratulations on your purchase of a UCL Advanced Safety Systems Portable Fall Arrest System. This equipment has been designed and manufactured to meet the needs of a discriminating operator in the variety of fall-arrest, confined space entry/retrieval and rescue situations. Safe, efficient and trouble free operation and maintenance of your equipment requires that you or anyone else who will be operating, maintaining or inspecting the equipment, read, understand and follow all the Safety, Operation, Maintenance and Inspection instructions contained in this manual, and in any related manuals referenced in this manual and/or supplied with the system. This manual covers the UCL ADVANCED PORTABLE FALL-ARREST SYSTEM and Accessories manufactured by Unique Concepts. Use the Table of Contents or Index as a guide when searching for specific information. WARNING This product is a part of a Man Rated Confined Space Entry/Retrieval System. The user must read, understand, and follow the instructions contained in the manual for each component or total system before using this equipment. Establish an appropriate training, maintenance, and inspection program for your people and the equipment. Failure to follow these instructions could result in serious injury or death. Keep this manual handy for frequent reference and to pass to new operators or visit our website for this manual at http://www.uclsafetysystems.com. Establish a regular training program for experienced and new operators per these instructions. Establish a regular maintenance and inspection program to keep the equipment in top condition. The UCL ADVANCED PORTABLE FALL-ARREST SYSTEM is a modular system of Portable Fall Arrest Anchor Posts, Extensions, and Support Bases designed to address a wide variety of Fall-Arrest and Confined Space Entry/Retrieval and Rescue applications. Modular components are labelled with the capacities and rating to which they were designed, tested, and manufactured. The rating of any system is considered to be the rating of the lowest rated component contained is the system. Do not use the equipment if rating labels are damaged or illegible. New labels are available from the manufacturer or your local authorized dealer. When ordering replacement labels, be sure to include: 1) The part number from the bottom right hand corner of the label, when available. 2) The serial number of the unit. 3) The part (item) number of the component (consult the appropriate section of this manual). 4) Any other numbers stamped on the components. 1 SAFETY ALERT SYMBOL This Safety Alert symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! The Safety Alert symbol identifies important safety messages on your UCL Equipment and in the manual. When you see this symbol, be alert to the possibility of personal injury of death. Follow the instructions in the safety message. Why is SAFETY important to you? 3 Big Reasons SIGNAL WORDS: Note the use of the signal words DANGER, WARNING, and CAUTION with the safety messages. The appropriate signal word for each message has been selected using he following guide-lines: Accidents Disable and Kill Accidents Cost You Money Accidents Can Be Avoided DANGER - Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations, or for hidden or unseen hazards. WARNING - Indicates a potentially hazardous situation that if not avoided, could result in death or serious injury, and includes obvious and hidden hazards. It may also be used to alert against unsafe practices. CAUTION - Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. 2 SAFETY YOU are responsible of the SAFE operation, maintenance and inspection of your UCL Advanced Portable Fall-Arrest System. YOU must ensure that you and anyone else, who is going to operate, maintain, inspect or work around the equipment be familiar with the operating and maintenance procedures and related SAFETY information contained in this manual. This manual will take you step-by-step through your working day and alerts you to all good safety and operating practices while using the equipment. Remember, YOU are the key to safety. Good safety practices not only protect you, but also the people around you. Make these practices a working part of your safety program. Be certain that EVERYONE operating this equipment is familiar with the procedures recommended and follows safety precautions. Remember, most accidents can be prevented. Do not risk injury or death by ignoring good safety practices. • • • • • Owners must give operating instructions to operators or employees before allowing them to use the equipment, and at least annually thereafter. The most important safety device on this equipment is a SAFE operator. It is the operator’s responsibility to read and understand ALL Safety and Operating instructions in the manual and to follow these. All accidents can be avoided. A person who has not read, been trained in using and understood all operating and safety instructions is not qualified to operate this equipment. An untrained operator exposes himself and others to possible serious injury or death. Do not modify the equipment in any way. Unauthorized modification may impair the function and/or safety and could affect the life of the equipment. Think SAFETY! Work SAFELY! 2.1 GENERAL SAFETY 1. Read, understand and follow the User Manual and all safety signs before using, maintaining or inspecting the equipment. 2. Refer to and follow applicable ANSI, OSHA, CE or other Standards and local regulations. Comply with requirements of local regulations for your applications. 3. Establish an equipment–use training program for experienced employees. Only trained, competent persons shall use the equipment. An untrained operator is not qualified to operate the system. 4. Have a first-aid kit available for use should the need arise and know how to use it. 5. Provide a fire extinguisher for use in case of an accident. Store in a highly visible place. 6. Install and properly secure all guards and shields before operating. 7. Wear appropriate protective gear. This list includes but is not limited to: - A hard hat Safety glasses Protective shoes with slip resistant soles Heavy gloves Protective clothing Face protection 8. Review and follow the Pre-Operation Inspection before using a component in the system or the system itself. 9. Establish a regular Maintenance and Inspection program with your equipment and maintain detailed records. 10. Review safety related items and operating instructions with all personal on a regular basis. 11. Be aware of your environmental surroundings, be sure not to use the equipment during an electrical storm. (this equipment is conductive) 12. When using our winch with our equipment, the noise level does not exceed 70 dB(A). 3 2.2 OPERATING SAFETY 1. Read, understand and follow the User Manual and signs on the equipment before using, maintaining or inspecting the equipment. 2. Train all operators before allowing them to use the equipment. An untrained operator exposes themselves, bystanders and co-workers to possible serious injury or death. 3. Visually inspect the equipment and all auxiliary components and equipment before using. Correct any problems before using the equipment. 4. Securely anchor all winches and /or SRL’s before using, where applicable. 5. Use only certified anchor and connector components in your system. 6. Use only an approved full body harness for the workers. 7. Always work in teams. One person works in the confined space and the other one pays out the line and reels it in. 8. Do not use the winch when the brake wear indicator displays excessive wear, the overload indicator on the snap has been activated, or the manufacturer’s service interval has been exceeded. Return winch to manufacturer for service. (Refer to the appropriate Winch Operators Manual for detailed information on winch operation.) 9. Do not exceed the winch’s rated working load during operation. 10. Establish a regular training program for new and experienced workers. 11. Establish a detailed inspection program for your equipment and document the findings. Return the equipment to the manufacturer for rework if any problems are found. 4 12. Plan your work program before starting. Have the required people, equipment and procedures available to do the job. 13. Do not use the equipment around physical or environmental hazards. This list includes but is not limited to: a. Corrosion that may affect the structural integrity of the life line or other components . b. Chemicals which can degrade components and not be visible. c. Toxic gases: Rescuers or workers can be killed in toxic environments. d. Heat or elevated temperatures. e. Moving machinery: Workers or auxiliary equipment can be contacted by or pulled into moving components. f. Sharp edges: Workers or the equipment can be injured or damaged by sharp edges or components. g. Electrical hazards: Stay away from power lines or components carrying electrical power. h. Overload: Do not exceed rated working load limit during operation. i. Follow confined space regulations in Standards. 2.3 MAINTAINANCE/INSPECTION SAFETY 1. Read, understand and follow the User Manual and signs on the equipment before using, maintaining or inspecting the equipment. 2. ANSI, OSHA & CE require a regular inspection program for all Confined Space Entry/Retrieval Equipment and to maintain documented results of these inspections. Follow the inspection procedure contained in this manual and use the inspection form to document the results. 3. Keep instructional and safety signs clean and legible at all times. Clean or replace as required. 4. Lubricate winch as per instructions in the appropriate Winch Operators Manual. 5. Remove the equipment from service if a problem is found during the inspection. Return to an authorized repair depot or the factory for service. 3 OPERATING, NEW OPERATOR OR OWNERS The UCL ADVANCED PORTABLE FALLARREST SYSTEM is designed to attach to a person working at a height to provide protection against injuries resulting from a fall. Various accessories address a variety of fall-arrest requirements, as well as confined space entry/retrieval and rescue needs. Every new operator must read, understand and follow the instructions in all applicable manuals. No one should be allowed to use the equipment without training. The training should be reviewed with experienced operators on a regular basis. At regular intervals perform a detailed inspection of the equipment and document the results. Remove from service if deficiencies are found. Alterations or misuse of this equipment or failure to follow instructions, may result in serious injury of death. It is the responsibility of the owner’s organization or operator to read this manual and to train all other operators before they start working with the equipment. Follow all safety instructions exactly. Safety is everyone’s business. By following recommended procedures, a safe working environment is provided for the operator, bystanders and the area around the work site. Untrained operators are not qualified to operate the equipment. Many features incorporated into this equipment are the result of suggestions made by customers like you. Read this manual carefully to learn how to operate the equipment safely and how to set it to perform as intended. By following the operating instructions in conjunction with a good maintenance program, your equipment will provide many years of trouble-free service. 5 3.1 PORTABLE FALL ARREST POST 3.1.1 General The UCL ADVANCED PORTABLE FALL-ARREST POST is a modular unit consisting of a 3 section tubular body, constructed of welded aluminum, featuring: 1. A head assembly equipped with 3 independent swivel tie-off rings. 2. Various accessories to address different situations. 3. Adjusting screws for vertical leveling of the Fall-Arrest Post when installed on inclined surfaces. 4. Featuring adjustable height option from 33.0 (840mm) to 57.5 (1460mm) inches. WARNING WARNING Figure 3.1.1 The Davit Arm Assembly and Anchor Post Extension have some application restrictions when used in different types of applications. Use of Portable Fall-Arrest System Accessories may affect the rating of the Portable Fall-Arrest System Anchor Post in various situations. The rating of any system is the rating of the lowest rated component in that system. 7 OPERATING SAFETY 1. Read, understand and follow the User Manual and signs on the equipment before using, maintaining or inspecting the equipment. 2. Train all operators before allowing them to use the equipment. An untrained operator exposes themselves, bystanders and workers to possible serious injury or death. 3. Visually inspect the equipment and all auxiliary components and equipment before using. Correct any problems before using the equipment. 4. Securely anchor the winch before using. 5. Use only certified anchor and connector components in your system. 6. All anchor points, or mounting/setup locations for permanent or portable systems must be approved to local standards by a qualified engineer. 7. Use only an approved body harness for the workers. 8. Always work in teams. One person works in the confined space and the other one pays out the line and reels it in. 9. Do not use the winch when the brake wear indicator displays excessive wear, the overload indicator on the snap has been activated, or the manufacturer’s service interval has been exceeded. Return winch to manufacturer for service. (Refer to the appropriate Winch Operators Manual for detailed information on winch operation.) 10. Use only retractable lifelines or shock absorbers with a maximum arrest force (MAF) rating equal to or lower than ½ of the strength of the lowest rated component of your system. 6 11. Establish a regular training program for new and experienced workers. 12. Establish a detailed inspection program for your equipment and document the findings. Return the equipment to the manufacturer for rework if any problems are found. 13. Plan your work program before starting. Have the required people, equipment and procedures available to do the job. 14. Do not use the equipment around physical or environmental hazards. This list includes but is not limited to: a. Corrosion that may affect the structural integrity of the life line or other components. b. Chemicals which can degrade components and not be visible. c. Toxic gases: Rescuers or workers can be killed in toxic environments. d. Heat or elevated temperatures. e. Moving machinery: Workers or auxiliary equipment can be contacted by or pulled into moving components. f. Sharp edges: Workers or the rescue equipment can be injured by or damaged by sharp edges or components. g. Electrical hazards: Stay away from power lines or components carrying electrical power. h. Overload: Do not exceed rated working load limit during operation. i. Follow confined space regulations in Standards. j. Noise: wear appropriate noise protection where necessary. k. Environmental hazards: do not operate equipment during electrical storms. When using a UCL ADVANCED PORTABLE FALL-ARREST SYSTEM the rating of any particular system is defined as the rating of the lowest rated component in the system. Check the rating label on each system component before using to ensure that the rating meets all applicable regulatory requirements. Do not use any equipment on which any of the warning, rating or other labels have been removed, become damaged, or are otherwise illegible. Refer to Section 5 of this manual “Labels”, or to the appropriate section of the applicable system manual for information on ordering replacement labels. 3.1.2 Regulations governing Fall Protection, Confined-Space Entry/ Retrieval and Rescue Procedures vary with jurisdiction. It is the responsibility of the owner and/or user of this equipment to be aware of applicable regulations and ensure that equipment selected for each job complies with these requirements. Refer to the appropriate section of this or any other applicable manuals for specific information on the installation and use of the type of base you are using prior to using the system. Setting Up the Portable Fall Arrest Post The UCL ADVANCED PORTABLE FALLARREST SYSTEM POST is designed for use with a variety of portable and permanent mount support bases. Consult the appropriate section of this manual or separate manuals when setting up or installing any UCL Portable Fall Arrest Bases. Step 1: Before setting up for any work at heights, fall arrest, or confined space entry be sure that you have all equipment required to safely carry out the work to be performed, and to meet all applicable standards and regulations for your area. Step 2: Set-up or locate the Portable Fall Arrest System Base intended for use in the application according to the instructions in the applicable section of this manual. Ensure that the base is structurally sound and free of any corrosion or contamination which may affect the insertion of the connecting pin or the structural integrity of the base. 8 Step 3: As shown in Fig. 3.1.3, insert the Portable Fall Arrest Post (13) between the base plates tabs (1) and visually align the ¾” holes as shown in Fig. 3.1.3.B. Secure the Post by inserting the ¾” pin (2) through the base plate tabs (1) and sleeve (13). Make sure the pin fully engages both the base plate tabs (1) and the entire Post to lock the Post firmly in place. Step 4: Extend the post (13) by loosening triscrew (4a) and removing section 1 pin (5) from section 1, Figure 3.1.2 A, lift section 2 and align the pin holes, secure section 2 in section 1 by fully engaging section 1 pin (5). The post should look like Figure 3.1.2 B. 12 Loosen tri-screw (4b) and lift section 3 and align pin holes with section 2, Figure 3.1.2 B and secure the Post section 3 by using section 2 pin (6). The post should look like Figure 3.1.3 A. 4b Hand tighten both tri-screws (4). Step 5: The Portable Fall-Arrest Post (Fig. 3.1.3A) must be in a vertical position at all times when it is being used as a Fall13 Arrest anchor point. Depending on the type of base you are using the Post may be leveled by using the adjuster screws (3) the base plate (10) or a combination of these. The adjuster screws are alternately loosened and tightened to level the Post. 113 6 4a 5 Figure 3.1.2 A Figure 3.1.2 B 9 12 8 9 Step 6: Install any accessories (eg. Anchor Post Extension) that installs in the sleeve (9) at the top of the Portable Fall Arrest Post. Refer to the applicable section of this or other applicable accessory manuals for any accessories being used with this system. 8 8 Step 7: Depending on the nature of the entry and the standards and regulations 7 governing Confined Space Entry/ Retrieval and Rescue requirements in your area, a Personal Fall-Arrest System (PFAS) connected to the entrant may be required. It is the responsibility of the operator to be aware of these requirements and follow them. Always wear a full body harness when attached to a PFAS to minimize potential injury. 1 2 3 4 5 6 7 8 6 4 5 Step 8: Once the system is set-up inspect all components, fasteners, and other parts for wear, damage, corrosion, looseness, or any other condition that may reduce the integrity of the system. Components which are worn, damaged, corroded, or loose, must be tagged, marked with “DO NOT USE” or like wording and prevented from being used until repaired or replaced as required. 11 Step 9: Following all instructions contained in the manufacturer’s instructions for any PFAS or any other devices being used, the appropriate section of this manual or other manuals for any UCL Accessories 3 being used, and all applicable standards or regulations governing Fall Protection, Confined Space Entry/ Retrieval and Rescue for your area proceed with the work. 10 8 14 9 10 11 12 13 14 13 1 3 Figure 3.1.3 A 10 2 Figure 3.1.3 B Base Tab Plates ¾” Pin Adjuster Screw Tri-Screw Section 1 Pin Section 2 Pin Section 3 Pin Swivel Tie Off Rings Extension Sleeve Uni-Anchor Plate Carrying Handle Davit Anchor Ring PFA Post HLL Anchor Ring 3.1.3 Using the Portable Fall Arrest Mast for Horizontal Lifeline (HLL) Applications HLL Anchor Ring 3.1.3.1 General Figure 3.1.5 The UCL Advanced Portable Fall Arrest Mast can be used for most temporary Horizontal Lifelines (HLL) applications, therefore using existing mounting bases as the temporary base for HLL applications. HLL Follow all labels carefully when setting up for HLL applications and refer to the chart when unsure of load ratings. HLL Tie-back HLL 3.1.3.2 Setting up the Portable Fall Arrest Post for HLL use When using this post for HLL applications, it is critical to know when to use a tie-back and when not to use a tie-back to support the HLL loads. Refer to the chart Figure 3.1.6 to confirm what loads can be sustained by the UCL Portable Fall Arrest Post unsupported by a tieback. HLL Tie-back or Intermediate Anchor HLL Figure 3.1.4a Figure 3.1.4b Step 1: Follow set-up instructions in section 3.1.2 of this manual. Step 2: The post can be used without the installation of a tie-back as shown in Figure 3.1.4a. Refer to the “HLL Chart Positions & Ratings”, Figure 3.1.6 for maximum ratings without the use of a tie-back. Step 3: Using the mast with the second and/or third stage erected (Positions 4, 3 & 2) and HLL load ratings that exceed the load rating shown in the chart, Figure 3.1.6, must have tie-backs installed as shown in Figure 3.1.4b. Step 4: Using the davit arm with a HLL requires the third section, (Positions 4 & 3) of the mast to be erected to install the davit arm sleeve. Refer to the chart to verify tie-back use. Refer to section 3.3.3.1 of this manual for Davit Arm set-up. Step 5: Install HLL using the carabineer supplied with the HLL assembly to the HLL Anchor Ring provided on the mast as shown in Figure 3.1.5. Follow all manufactures instruction carefully when installing a HLL. If you require a tie-back, install the tieback using the opposite eye across from the installed HLL on the HLL Anchor Ring. Tie-back anchors must be designed and approved by the manufacturer (UCL) and the structure mounting requirements approved by a qualified engineer. Call UCL to purchase the suitable tie-back for the application. The UCL Portable Fall Arrest Post with HLL Anchor Ring can also be used as an intermediate for a HLL to spanning across longer distances. 11 UCL Advanced Aluminum Fall Arrest Anchor Post Model#: 8516691 Capital Safety USA: 800.328.6146 • Canada: 800.387.7484 • Asia: + 852 2992 0381 • Australia/New Zealand: 800 245 002 • Europe, Middle East, Africa: +33 (0) 497 10 00 10 • Northern Europe: +44 (0) 1928 571324 www.capitalsafety.com • [email protected] SPECIFICATIONS PAGE 2 OF 2 ISO 9001 REGISTERED 3.2 MOUNTING BASES 3.2.1 Uni-Anchor Plates Uni-Anchor Plates are designed to be permanently welded to existing structures in locations of frequent work, or where use of portable base is impractical. These mounting plates are compatible with all UCL ADVANCED PORTABLE FALL-ARREST SYSTEM Posts and Accessories. UniAnchor Plates permanently address Portable Fall-Arrest Anchor Post mounting base requirements for steel structures. 3.2.2 Installing Uni-Anchor Plates Specific installation instructions are beyond the scope of this product operator’s manual. Consult UCL Safety Systems Product Specification Sheets for detailed information on welding procedures, mounting requirements and application restrictions. 3.2.3 Installing Portable Mounting Bases Specific installation instructions are beyond the scope of this product operator’s manual. Consult UCL Safety Systems Product Specification Sheet # 16997 (I-Beam Clamp Base) or 16804 (Tripod Base) for detailed information on mounting procedures, mounting requirements and application restrictions. 3.2.3 Set-up of the Portable Fall-Arrest Post Install and level the Portable Fall-Arrest Post as outlined in Section 3.1.2. WARNING WARNING All anchor points or mounting/set-up locations for permanent or portable systems must be approved to local standards by a qualified engineer and must comply with all mounting requirements and application restrictions as outlined on the applicable UCL Product Specification Sheet. Failure to follow this restriction may result in serious injury or death. 13 3.3 3.3.1 PORTABLE FALL-ARREST POST ACCESSORIES General The UCL ADVANCED PORTABLE FALLARREST POST may be equipped with a variety of accessories to meet additional confined space entry/retrieval, rescue, or fall protection requirements. Use of these accessories may affect the rating and load carrying capacities of the Portable Fall-Arrest Post. Be aware of any limitations imposed on the system by the use of various accessories, and follow any restrictions given on the various product specification sheets, warning labels, this manual and/or related manuals. All UCL ADVANCED PORTABLE FALLARREST SYSTEM and Accessories are designed for use with shock absorbers and retractable devices having a Maximum Arrest Force (MAF) rating of 900 lb. (4 kN) or less. Shock absorbers and retractable devices must be installed, maintained and used according to the manufacturer’s instructions. 14 WARNING WARNING The 14-inch Anchor Post Extension and Davit Arm Assembly have some application restrictions when used in different types of applications. The use of these accessories derates the system to two workers tied of to the swivel tie-off head (8), Fig.3.1.3. Failure to follow this restriction may result in serious injury or death. 3.3.2 14” Anchor Post Extension 15 The 14 inch Post Extension (Pt.# 16692) is designed to provide a single fall-arrest tie-off point 14 inches above the post’s swivel tie-off rings (See Figure 3.3.1). Use of the 14 inch Post Extension de-rates the Portable Fall-Arrest Post to only two anchor points on the swivel tieoff rings. 9 14 For use of the Anchor Post Extension & Davit Arm Assembly together refer to Section 3.3.3 of this manual. 3.3.2.1 Set-Up of the 14” Anchor Post Extension Install the Portable Fall-Arrest Post following the installation procedure in Section 3.1.2. Step 1: Shown in Fig. 3.3.1, insert the 14-inch Post Extension (14) into the post (9). Pin the post into position by aligning the holes and inserting the ½ inch pin (7) completely through the Post. 8 7 Step 2: Attach the Fall-Arrest Device to the anchor point eye (15). 3.3.2.2 Using the 14” Anchor Post Extension Connect a shock absorber/ retractable device using a sufficiently rated carabineer to anchor point eye (15). Using the 14” inch anchor post extension (14) limits the use of only 2 attendants anchored to the Portable Fall Arrest post swivel rings (8) for fall protection. Figure 3.3.1 15 3.3.3 Anchor Post Davit Arm Assembly The Anchor Post Davit Arm (Pt.# 16693) is designed to provide a means of access/egress, rescue, and material handling applications (See Figure 3.6.1). Use of the Anchor Post Davit Arm de-rates the Portable Fall-Arrest Post to only two anchor points on the swivel tie-off rings. 10 3 Using the 14” Anchor Post Extension combined with the Anchor Post Davit Arm de-rates the Portable Fall Arrest Post to only one anchor point on the swivel tie-off rings. 3.3.3.1 Set-Up of the Anchor Post Davit Arm Assembly Install the Anchor Post/ Davit Arm Assembly starting with and following the installation procedure in Section 3.1.2. Step 1: Shown in Figure 3.3.2.1, clamp the Davit Arm Sleeve (8) over Section 3 (7) of the Portable Fall Arrest Post. Step 2: Install and secure the Davit Arm Sleeve (8) by closing the sleeve around section 3 (7), Figure 3.3.2.1and hand tightening the clamp knob screws (12) shown in Figure 3.3.2.2. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 13 5 2 3/8” Pin Assembly Davit Anchor Eye Cable Assembly U-Bracket Carabineer Section 2 Section 3 Davit Arm Sleeve Davit Arm Receiver Tube Head Pin Assembly Clamp Screw Knobs PFA Post Davit Head Assembly Mounting Brackets 4 9 7 14 8 6 Figure 3.3.2 11 8 16 Figure 3.3.2.1 Figure 3.3.2.2 Step 3: Insert the Davit Head Assembly (15) and align one of the three 3/8” pin holes in the Davit Arm Receiver Tube. Using the pin (1) secure the Davit Arm into position and to vary the offset. Step 4: Shown in Figure 3.3.2.4, secure the cable assembly (3) to the Portable Fall Arrest Post (13) using the carabineer (5) provided and connecting it to the Davit Arm Anchor Eye (2), Figure 3.3.2.5. The Portable Fall Arrest Post may be used as a fall arrest anchor point during a rescue scenario. Alternative anchor points for fall protection use should be identified and planned for use during a rescue scenario. 9 1 3 5 2 Figure 3.3.2.4 Figure 3.3.2.3 3.3.3.2 Using the Davit Arm Assembly The Davit Arm Assembly is designed with offset adjustability and 360 degree rotation. This Davit Arm Assembly allows the combined use of an entry/ retrieval winch and a self-retracting lifeline (SRL). See Section 3.3.4 for details on mounting the winch and SRL. Step 1: Adjust the offset by pulling the pin assembly (1) and selecting the one of three holes offered in the Davit Arm receiver tube (9) as shown in Figure 3.3.2.3. 3.3.3.3 Rescue The Davit arm can be rotated 360 degrees in a rescue/ retrieval situation so an injured worker can be moved to a safe environment. The Portable Fall Arrest Post must be used in a vertical position at all times to effectively rotate the Davit Arm. 17 3.3.4 Mounting Brackets for Winch and SRL The mounting brackets are for use with the Davit Arm Assembly. Winches and SRL’s must have a 310 lbs working load and SRL used with the system must have an MAF rating of 900 lbs or less. 3.3.4.1 Set-up of the Mounting Brackets The mounting brackets will be bolted onto the Davit Arm Assembly when shipped from the manufacturer. The brackets are arranged to most common Winch/ SRL configuration. If these brackets need to be repositioned to suit your application, remove the two bolts securing the bracket to the Davit Arm Receiver Tube (9) shown in Figure 3.3.3, reposition to other bracket mount location and replace bolts and tighten. WARNING WARNING The Adaptor Brackets for your winch or SRL must be offset to the side that the crank handle is on to eliminate interference between the crank handle and the Davit Arm Assembly and the mounting brackets. Not following these instructions can impair retrieval capabilities that can cause serious injury or death. Bracket bolts 9 Figure 3.3.3 9 Bracket mount locations 3.3.4.2 Using the Mounting Brackets Install and use the winch and/or SRL according to manufacturer’s instructions. Proper operation and maintenance of the winch and/or SRL are critical to the safe usage of your UCL ADVANCED PORTABLE FALL ARREST SYSTEM. 18 3.3.5 Winch and SRL Operation Shown with the accessories in Section 3.3, is the UCL “Basic” Man-Rated Winch available for use with the UCL ADVANCED PORTABLE FALL-ARREST SYSTEM. The winch is necessary for worker positioning and rescue situations when using the Davit Arm Assembly. The winch is available in a variety of lifeline capacities, and lifelines are available in a variety of lengths and materials. Proper operation and maintenance of the winch are outlined in the “Basic Winch Operator’s Manual”, UCL Pt. # 16182 supplied with every winch. Winches and SRL’s must used and maintained in accordance with the manufacturer’s instructions, please refer to the instruction manual provided with your winch or SRL. 3.7 STORAGE Prior to storage, the Portable Fall Arrest System should be thoroughly inspected and maintained. Return for repair or replacement of any worn or damaged components to prevent any unnecessary down time at the next use. Follow this procedure: 1. Thoroughly clean the Portable Fall Arrest system using mild soap on the body and labels. Be sure the labels are legible. Refer to Section 5 for information on ordering replacement labels if any are damaged or become illegible. 2. Use a neutralizing solution to clean lifeline. This is particularly important if the unit had been used in corrosive or toxic environments. 3. Perform a complete inspection of the unit and document the results. 4. Touch up all nicks and scratches to prevent corrosion. 5. Store in a cool dry place. 19 4 MAINTENANCE AND INSPECTION MAINTENANCE/INSPECTION SAFETY 1. Read, understand and follow the User Manual and signs on the equipment before using, maintaining or inspecting the equipment. 2. ANSI and OSHA requires a regular inspection program for all Confined Space Entry/Retrieval Equipment and to maintain documented results of these inspections. Follow the inspection procedure contained in this of any other applicable the manual and use the inspection form(s) to document the results. 4.1 Maintenance 4.1.1 Maintenance Intervals 3. Keep instructional and safety labels clean and legible at all times. Clean or replace as required. See Section 5 for label information and part numbers. 4. Lubricate winch as per instructions in Winch Operator’s Manual. 5. Remove the equipment from service if a problem is found during the inspection. Return to an authorized repair depot or the factory for service. Daily Annually or As Required 1. Visual Inspection Perform a complete visual inspection. Refer to Section 4.2.1. Remove from service if a defect is found. Refer to Winch Operator’s Manual for visual inspection procedure for the UCL Basic winch. 1. Clean Portable Fall Arrest System Thoroughly clean the Portable Fall Arrest system using mild soap on the body and labels. Be sure the labels are legible. Refer to Section 5 for information on ordering replacement labels if any are damaged or become illegible. Weekly 1. Functional Inspection Perform a functional inspection. Refer to Section 4.2.2. Record results and keep documentation. 20 2. Complete Inspection Perform a complete inspection. Refer to Section 4.2 & 4.3. Record results and keep documentation. 4.2 Inspection 4.2.1 Visual Inspection A complete visual inspection should be performed on the Portable Fall-Arrest System equipment you are using prior to the operation. The following items should be checked; and the results recorded on the “Inspection Log” sheet (see Section 4.3). 1. Labels Check that all labels are clean and legible. Clean the labels if any are dirty using a mild soap and a damp cloth. Replace if any are illegible (Refer to Section 5 for a listing of all labels). 2. Fasteners Check that all screws and other fasteners are tight. If any are loose, tighten as required. Contact your local dealer or UCL manufacturer for any replacement fasteners that may be required 3. Structural Components Check the components for cracks, dents, bends, or breaks. Minor cosmetic damage in the component body will not affect the function of the Portable Fall-Arrest System. However if there are major dents or any other structural damage, the unit should be removed form service and returned to the manufacturer for service. 4. Corrosion Check all components for damage from corrosion. Although all components resist corrosion, working in corrosive environments can lead to damage. Inspect all structural components and fasteners for signs of damage. If corrosion damage is found, remove from service and return to the manufacturer for service. 5. Basic Winch Inspection Check the winch following the procedure in the Basic Winch Operator’s Manual, Part # 16182 and carefully document all findings as listed. 21 4.2.2 Functional Inspection A functional check should be performed on the Portable Fall-Arrest System prior to every use. The following functional tests should be done; and the results recorded on the “Inspection Log” sheet (Section 4.3). 1. System Operation and Adjustments The Portable Fall Arrest System contains operational parts that may include pulleys and /or rollers. These parts must be carefully checked for chips, cracks, or worn areas that can cause malfunction during operation of the system. Make sure that all the adjustment points are in full functional condition. This may include parts that contain pins, bolts, tri-screws, and adjusting screws. There are also mechanical adjustments which may include, adjustable legs, sleeves, adjustable sliding blocks, and brackets. These areas must be kept clean from debris and corrosion for proper functional use. If any part of the system that includes all listed items above becomes damaged contact your local dealer or manufacturer for parts and/or service. 2. Basic Winch Inspection Refer to the Basic Winch Operator’s Manual, Pt.# 16182 (where applicable) for proper functional inspection procedures for the Basic winch and lifeline. 3. SRL and other Accessory Inspection Refer to the manufacture’s operator’s manual or instructional material for proper functional inspection procedures for SRL’s and accessories not covered by this manual. 22 21 6 SPECIFICATION SHEETS 6.1 General These specification sheets contain information necessary for the proper installation and use of the equipment mentioned in this manual. These specifications contain application specific ratings and mounting requirements determined through design and testing. Please read and follow these specification sheets carefully to ensure the proper installation of each item. 24 UCL Advanced Aluminum Fall Arrest Anchor Post Model#: 8516691 SPECIFICATIONS PAGE 1 OF 2 Model 8516691 includes the following: 8516691 8516692 8516693 8517344 8517266 8517345 8517346 Capital Safety USA: 800.328.6146 • Canada: 800.387.7484 • Asia: + 852 2992 0381 • Australia/New Zealand: 800 245 002 • Europe, Middle East, Africa: +33 (0) 497 10 00 10 • Northern Europe: +44 (0) 1928 571324 www.capitalsafety.com • [email protected] ISO 9001 REGISTERED UCL Advanced Aluminum Fall Arrest Anchor Post Model#: 8516691 Capital Safety USA: 800.328.6146 • Canada: 800.387.7484 • Asia: + 852 2992 0381 • Australia/New Zealand: 800 245 002 • Europe, Middle East, Africa: +33 (0) 497 10 00 10 • Northern Europe: +44 (0) 1928 571324 www.capitalsafety.com • [email protected] SPECIFICATIONS PAGE 2 OF 2 ISO 9001 REGISTERED UCL Advanced Aluminum Portable Fall Arrest Anchor Post Extension Model#: 8516692 SPECIFICATIONS PAGE 1 OF 2 Model 8516692 includes the following: 8516692 8516691 Capital Safety USA: 800.328.6146 • Canada: 800.387.7484 • Asia: + 852 2992 0381 • Australia/New Zealand: 800 245 002 • Europe, Middle East, Africa: +33 (0) 497 10 00 10 • Northern Europe: +44 (0) 1928 571324 www.capitalsafety.com • [email protected] ISO 9001 REGISTERED UCL Advanced Aluminum Portable Fall Arrest Anchor Post Extension Model#: 8516692 Capital Safety USA: 800.328.6146 • Canada: 800.387.7484 • Asia: + 852 2992 0381 • Australia/New Zealand: 800 245 002 • Europe, Middle East, Africa: +33 (0) 497 10 00 10 • Northern Europe: +44 (0) 1928 571324 www.capitalsafety.com • [email protected] SPECIFICATIONS PAGE 2 OF 2 ISO 9001 REGISTERED UCL Advanced Aluminum Portable Fall Arrest Anchor Post Davit Arm Assembly Model#: 8516693 SPECIFICATIONS PAGE 1 OF 2 Model 8516693 includes the following: 8516693 8516691 Capital Safety USA: 800.328.6146 • Canada: 800.387.7484 • Asia: + 852 2992 0381 • Australia/New Zealand: 800 245 002 • Europe, Middle East, Africa: +33 (0) 497 10 00 10 • Northern Europe: +44 (0) 1928 571324 www.capitalsafety.com • [email protected] ISO 9001 REGISTERED UCL Advanced Aluminum Portable Fall Arrest Anchor Post Davit Arm Assembly Model#: 8516693 Capital Safety USA: 800.328.6146 • Canada: 800.387.7484 • Asia: + 852 2992 0381 • Australia/New Zealand: 800 245 002 • Europe, Middle East, Africa: +33 (0) 497 10 00 10 • Northern Europe: +44 (0) 1928 571324 www.capitalsafety.com • [email protected] SPECIFICATIONS PAGE 2 OF 2 ISO 9001 REGISTERED 7 REPLACEMENT PARTS 7.1 General These drawings are to provide you with an easy reference to order replacement labels and parts when required. Please follow each of the drawings to locate the part numbers required to order from UCL by either referencing the bill of materials on the right hand side of the drawing and then locating the balloon pointing out the replacement part for verification or visa versa. 25 31 Capital Safety USA: 800.328.6146 • Canada: 800.387.7484 • Asia: + 852 2992 0381 • Australia/New Zealand: 800 245 002 • Europe, Middle East, Africa: +33 (0) 497 10 00 10 • Northern Europe: +44 (0) 1928 571324 www.capitalsafety.com • [email protected] Printed in Canada Issue Date: March 20, 2007 Revision Number: 02 Part Number: 8517451